3D Printing Materials and Technologies for Orthopaedic Applications.

Three-dimensional (3D) printing technologies enables fast prototyping of complex 3D objects with ever improving printing qualities. To date, 3D printing has been found useful in areas such as manufacturing, industrial design, aerospace, dental and medical industries, and many others. In this article, we review recent advances of 3D printing technologies for terahertz (THz) applications. Different 3D printing technologies and printable materials are first discussed and compared. 3D-printed THz components and devices, which are categorized as waveguides/fibers, antennas, and quasi-optical components, are further demonstrated. It is found that the performances and functionalities of 3D-printed THz devices have been greatly enhanced, while the operating frequencies have been increased from the lower end of THz range to over 1 THz region. With further development of novel materials and printing techniques, it is believed that 3D printing technologies will play an important role in the realization of THz components for efficient control and manipulation of THz waves.

Background: Three-dimensional (3D) printing technology has rapidly emerged as a transformative tool in medicine, enabling the conversion of two-dimensional scans into highly accurate 3D models. This technology, especially when combined with artificial intelligence (AI) and advanced materials, offers numerous applications in surgical planning, simulation-based training, and patient-specific care. Methods: This review examines current literature and case studies on the use of 3D printing technology in various fields of medicine, especially in surgical specialties. Key applications include surgical planning, mock surgeries, biopsy guide creation, and customized implant fabrication across various surgical fields. Results: 3D printing is transforming surgery by enabling precise visualization of tumors and critical structures, significantly enhancing preoperative planning for conditions such as bone, soft tissue (e.g., neuroblastomas), renal, and maxillofacial tumors. In reconstruction surgeries, patient-specific 3D-printed implants ensure better anatomical compatibility, particularly in maxillofacial, neurosurgical, and vascular applications. Puncture guides improve procedural accuracy in interventions like percutaneous nephrolithotripsy. Detailed anatomical models aid in simulation-based training, increasing preparedness for complex procedures. Additionally, patient-specific implants and AI-integrated decision support systems are paving the way for more personalized and efficient surgical care. Conclusions: 3D printing technology, especially when combined with AI, is reshaping modern surgery by improving both accuracy, safety, and personalized healthcare. Its applications extend across multiple specialties, offering new possibilities in surgical planning, training, and patient-specific treatments. As AI and bioprinting continue to evolve, the potential for real-time applications, such as live-printed tissue implants and enhanced decision support, could drive the next phase of innovation in various fields.

BackgroundTemporary implant-retained restorations are required to support function and esthetics of the masticatory system until the final restoration is completed and delivered. Acrylic resins are commonly used in prosthetic dentistry and lately they have been used in three-dimensional (3D) printing technology. Since this technology it is fairly new, the number of studies on their susceptibility to microbial adhesion is low. Restorations placed even for a short period of time may become the reservoir for microorganisms that may affect the peri-implant tissues and trigger inflammation endangering further procedures. The aim of the study was to test the biofilm formation on acrylamide resins used to fabricate temporary restorations in 3D printing technology and to assess if the post-processing impacts microbial adhesion.MethodsDisk-shaped samples were manufactured using the 3D printing technique from three commercially available UV-curable resins consisting of acrylate and methacrylate oligomers with various time and inhibitors of polymerization (NextDent MFH bleach, NextDent 3D Plus, MazicD Temp). The tested samples were raw, polished and glazed. The ability to create biofilm by oral streptococci (S. mutans, S. sanguinis, S. oralis, S. mitis) was tested, as well as species with higher pathogenic potential: Staphylococcus aureus, Staphylococcus epidermidis and Candida albicans. The roughness of the materials was measured by an atomic force microscope. Biofilm formation was assessed after 72 h of incubation by crystal violet staining with absorbance measurement, quantification of viable microorganisms, and imaging with a scanning electron microscope (SEM).ResultsEach tested species formed the biofilm on the samples of all three resins. Post-production processing resulted in reduced roughness parameters and biofilm abundance. Polishing and glazing reduced roughness parameters significantly in the NextDent resin group, while glazing alone caused significant surface smoothing in Mazic Temp. A thin layer of microbial biofilm covered glazed resin surfaces with a small number of microorganisms for all tested strains except S. oralis and S. epidermidis, while raw and polished surfaces were covered with a dense biofilm, rich in microorganisms.ConclusionsUV-curing acrylic resins used for fabricating temporary restorations in the 3D technology are the interim solution, but are susceptible to adhesion and biofilm formation by oral streptococci, staphylococci and Candida. Post-processing and particularly glazing process significantly reduce bacterial biofilm formation and the risk of failure of final restoration.

This study evaluates the three-dimensional (3D) printing materials used in Fused Deposition Modeling (FDM) printing technology. 3D printing technology has been developing strongly, becoming an effective support tool in production and research. The 3D printing process involves many stages, with many parameters affecting the quality and properties of the product, in which 3D printing material is one of many essential factors affecting that process. The study conducts a comprehensive assessment of the most common materials in 3D printing technology to determine the advantages and limitations of precisely five types of materials: Polylactic acid, acrylonitrile butadiene styrene, polyethylene terephthalate glycol-modified, thermoplastic polyurethane, and acrylonitrile styrene acrylate. With 3D printing, parameters such as sintering temperature, printing speed, and layer thickness are kept constant. These parameters are applied equally to all five material samples. The experiment evaluates the tensile strength of materials. The study results provide an overview of the properties and applicability of 3D printing materials, helping to select materials suitable for specific FDM 3D printing technology applications.

BackgroundRecent advances in 3D printing technology, and biomaterials are revolutionizing medicine. The beneficiaries of this technology are primarily patients, but also students of medical faculties. Taking into account that not all students have full, direct access to the latest advances in additive technologies, we surveyed their opinion on 3D printing and education in this area. The research aimed to determine what knowledge about the use of 3D printing technology in medicine, do students of medical faculties have.MethodsThe research was carried out in the form of a questionnaire among 430 students of the Medical University of Silesia in Katowice (Poland) representing various fields of medicine and health sciences. The questions included in the survey analyzed the knowledge of the respondents for 3D printing technology and the opportunities it creates in medicine.ResultsThe results indicate that students do have knowledge about 3D printing obtained mainly from the internet. They would be happy to deepen their knowledge at specialized courses in this field. Students appreciated the value of 3D printing in order to obtain accurate anatomical models, helpful in learning. However, they do not consider the possibility of complete abandonment of human cadavers in the anatomy classes. Their knowledge includes basic information about current applications of 3D printing in medicine, but not in all areas. However, they have no ethical doubts regarding the use of 3D printing in any form. The vast majority of students deemed it necessary to incorporate information regarding 3D printing technology into the curriculum of different medical majors.ConclusionThis research is the first of its kind, which allows for probing students' knowledge about the additive technologies in medicine. Medical education should be extended to include issues related to the use of 3D printing for medical applications.

Background: Three-dimensional (3D) printing technology is increasingly commercially viable for pre-surgical planning, intraoperative templating, jig creation and customised implant manufacture. The challenging nature of scaphoid fracture and nonunion surgery make it an obvious target. The aim of this review is to determine the use of 3D printed technologies in the treatment of scaphoid fractures. Methods: This is a review of the Medline, Embase and Cochrane Library databases examining studies aimed at therapeutic use of 3D printing, also known as rapid prototyping or additive technology, in the treatment of scaphoid fractures. All studies published up to and including November 2020 were included in the search. Relevant data extracted included modality of use (as template/model/guide/prosthesis), operative time, accuracy of reduction, radiation exposure, follow-up duration, time to union, complications and study quality. Results: A total of 649 articles were identified, of which 12 met the full inclusion criteria. Analysis of the articles showed that 3D printing techniques can be utilised in myriad ways to aid planning and delivery of scaphoid surgery. Percutaneous guides for Kirschner-wire (K-wire) fixation of non-displaced fractures can be created; custom guides can be printed to aid reduction of displaced or non-united fractures; patient-specific total prostheses may recreate near-normal carpal biomechanics and a simple model may help graft harvesting and positioning. Conclusions: This review found that the use of 3D printed patient-specific models and templates in scaphoid surgery can improve accuracy and speed, and reduce radiation exposure. 3D printed prostheses may also restore near-normal carpal biomechanics without burning bridges for potential future procedures. Level of Evidence: Level III (Therapeutic).

This paper explores the possibility of using different 3d printing methods and materials in the production of polymer molds for injection molding applications. A mold producing a cube was designed using a commercial software. Following the standard 3d printing process, injection molds which could produce a cube were printed using different 3d printing materials and 3d printing technologies. The 3d printing technologies used were Stereolithography (SLA), Polyjet and Fused Filament Fabrication (FFF). A bench-top injection molding machine was used to inject polylactic acid (PLA) in these molds. The quality of the injected parts in terms of dimensional accuracy has been investigated. In some cases, the damage mechanism of the polymer molds has also been observed.

For decades we have used printers to print superheroes on the pages of comic books but could printing technologies actually be used to print real life superheroes? 3D and functional printing technologies have advanced greatly in recent years and even though these technologies cannot be used to print heroes themselves, they can certainly be used for equipment manufacturing. One character that could or may use 3D printing to rapidly produce prototypes and final versions of new technologies is Tony Stark. As the inventor and primary user of the Iron Man suit, Stark has designed a wearable suit that is not only a weapon but also protects him. However, in battle the suit can become damaged and require urgent repairs. To aid in these repairs, Tony Stark could turn to 3D printing technologies to produce new components for the suit. In this paper we will outline 3D printing technologies and describe their current applications. We will then discuss how 3D printing is being used to print electronics and the ramifications for Tony Stark, his Iron Man suit and the potential use for a real Iron Man suit.

Three-dimensional (3D) printing technology has arrived and is changing a philisophy of “management.” A 3D-printed product is made from a powder or resin and can virtually shape any item from a digital graphics file. This new printing device, however, poses several unforeseen questions. The 3D printing technology calls for time and cost considerations. Once a private firm actually begins to operationalize the new technology, it will have to measure both merit and demerit in terms of a ‘before-and after adaptation’ perspective, in addition to a future prospect of further advantages the device might bring. Similarly, perhaps this is the most important, the use of this new technology might part away with the significant role and function of the core technology in production of different matters. Considering these topics, this study attempts to focus on the 3D printing technology and its influence on technology management. It specifically discusses the impact of 3D printing technology applied to manufacturing companies on their cost, time, quality and activities. To answer this question, a cost structure is developed using the IDKKH method. The cost calculation is also considered using the Cost-Matrix method. After making model and matrix, possibilities are shown as research collaborators and outsourcing selection to organize with the concept of technology management. Through these analyses, problems are clarified, and the discussions indicate the results of introducing 3D printing technology, R & D innovation, and technology management

The article is devoted to the study of the history of the emergence and development of additive technologies in world artistic ceramics. The article analyzes information on the history of the emergence of additive technologies. The principle of operation of 3D printing equipment, features of its use, the most common areas of use and materials used in 3D printing have been considered. An analysis of the specifics of the technical characteristics of 3D printers and technologies for 3D printing with ceramic masses has been shown that the use of ceramic materials as raw materials for 3D printing is a progressive trend due to the emergence of the possibility of forming ceramic objects and products that are practically indestructible reproduction and replication using traditional methods. In this article, the authors have been analyzed the advantages and disadvantages of manufacturing ceramic products by 3D printing. It has been established that the main difference between the production of three-dimensional plastic or metal elements and ceramic elements is the main feature of the ceramic manufacturing technology, namely that the printout is not a ceramic product before firing in the oven, that is, without firing, it is simply an element printed from clay materials (that is, such a printout before firing is called the "green part" – an unprocessed element). Currently, there are no 3D printers that can immediately produce ready-made ceramic products, all elements printed from ceramic materials require drying and firing. But, despite this nuance, printers that print with clay materials are called ceramic 3D printers. As 3D printing can accurately realize the creative thinking of artists and designers, 3D printing technology is increasingly used in the creation of ceramic products and contemporary ceramic works. The authors of the article emphasize that three-dimensional printing with clay provides ceramists with completely new opportunities for creating ceramic products with a complex configuration, texture, etc. Ceramic artists from all over the world are already actively using this technology in their work. Therefore, part of the study is devoted to examples of the use of 3D printing technology in world artistic ceramics, as well as to the description and analysis of the most interesting achievements in this direction of creativity, according to the authors.

A biomimetic surface for water collection was successfully engineered using three-dimensional (3D) printing technology. The fused deposition modeling-type 3D printing was used to create a reusable mold. This was used to cast waveform microstructures on a hydrophobic polymer surface, which was induced by using stacked filaments. The etching was performed on the printed mold by using a chemical solvent to generate nano/micro pores, which enhanced the rolling-off motion of water droplets. To create a hydrophilic region on the hydrophobic surface, the metal deposition was achieved using a 3D-printed mask and the self-masking effect of the tilted tips of waveform microstructures. The metal array served as seeding points for the growth of water droplets in foggy conditions. As a result, the fabricated biomimetic surface exhibited the highest water-collecting performance (average 0.77 g for 10 min) compared with the other four different surfaces. This study demonstrates the use of 3D printing technology to rapidly and simply fabricate engineered (hybrid) surfaces for various applications involving facile control of wettability.

Thermal and acoustic performance evaluation of 3D-Printable PLA materials

Three-dimensional (3D) printing technologies are transforming the design and manufacture of components and products across many disciplines, but their application in the construction industry is still limited. Material deposition processes can achieve infinite geometries. They have advanced from rapid prototyping and model-scale markets to applications in the fabrication of functional products, large objects, and the construction of full-scale buildings. Many international projects have been realised in recent years, and the construction industry is beginning to make use of such dynamic technologies. Advantages of integrating 3D printing with house construction are significant. They include the capacity for mass customisation of designs and parameters to meet functional and aesthetic purposes, the reduction in construction waste from highly precise placement of materials, and the use of recycled waste products in layer deposition materials. With the ultimate goal of improving construction efficiency and decreasing building costs, the researchers applied Strand 7 Finite Element Analysis software to a numerical model designed for 3D printing a cement mix that incorporates the recycled waste product high-density polyethylene (HDPE). The result: construction of an arched, truss-like roof was found to be structurally feasible in the absence of steel reinforcements, and lab-sized prototypes were manufactured according to the numerical model with 3D printing technology. 3D printing technologies can now be customised to building construction. This paper discusses the applications, advantages, limitations, and future directions of this innovative and viable solution to affordable housing construction.

Three-dimensional printing technologies are mainly used to build objects with complex shapes and geometry, largely prototypes, and thanks to the possibility of building very thin layers of material with small pores, electrospinning technology allows for the creation of structures with filtration properties, in particular very small particles. The combination of these technologies creates new possibilities for building complex-shape composites that have not been comprehensively tested so far. The article describes the results of research on composites manufactured by combining samples prepared with two 3D printing technologies, Fused Filament Fabrication (FFF) and Photo-Curing of Liquid Polymer Resins (PJM) in combination with electrospinning (ES) technology. The surface morphology of composites manufactured from biocompatible materials was investigated using confocal laser scanning microscopy (CLSM) and contact angle measurements, and chemical composition analysis was studied using Fourier transform infrared spectroscopy (FTIR). This approach to creating composites appears to be an alternative to developing research for filtration applications. The article presents basic research illustrating the quality of composites produced by combining two unconventional technologies: 3D printing and electrospinning (ES). The analysis of the research results showed clear differences in the structure of composites produced with the use of various 3D printing technologies. The CLSM analysis showed a much better orientation of the fibers in the MED610 + PAN/gelatin composite, and the measurement of the contact angle and its indirect interpretation also for this composite allows for the conclusion that it will be characterized by a higher value of adhesion force. Moreover, such composites could be used in the future for the construction of filtering devices and in medical applications.

This paper deals with the design and experimental characterization of wideband discone antenna made of polylactid-acid (PLA) material using a three-dimensional (3D) printing technology. The proposed antenna is intended to have a wideband operating frequency of 700 MHz–6 GHz desirable for electromagnetic interference (EMI) sensors application. Here, the use of 3D printing technology is to realize the cone of the antenna, while the disc is implemented using a copper-sheet. To demonstrate feasibility of the proposed antenna, a conventional discone antenna made of all copper-sheets is also realized and experimentally characterized as comparison. From the characterization result, it shows that the proposed 3D-printed discone antenna has the –10 dB operating bandwidth range of more than 5.3 GHz from the frequency of 698 MHz. This measured operating bandwidth showed obviously wideband characteristics and was wider than the one of conventional discone antenna.